Substrate processing with reduced warpage and/or controlled strain

ABSTRACT

Provided are systems and methods for processing the surface of substrates that scan a laser beam at one or more selected orientation angles. The orientation angle or angles may be selected to reduce substrate warpage. When the substrates are semiconductor wafers having microelectronic devices, the orientation angles may be selected to produce controlled strain and to improve electronic performance of the devices.

BACKGROUND

1. Field of the Invention

The invention relates generally to systems and methods for processingthe surface of substrates, e.g., semiconductor wafers. In particular,the invention relates to such systems and methods that scan a beam alongselected orientation angles to reduce substrate warpage and/or controlsubstrate stresses and strains.

2. Description of Background Art

Microelectronic circuit and other microstructural features are createdon a substrate through the use of photolithographic technology.Typically, photolithography tools and processes are designed to imagesubstrates such as unstrained semiconductor wafers having asubstantially or perfectly flat wafer surface topography. Whileunprocessed semiconductor wafers may be initially unstrained, subsequentwafer processing may warp or otherwise uncontrollably strain the wafers.

In general, warped substrates such as semiconductor wafers areaccompanied with wasted tool operation time, increased wafer processcosts, and reduced overall processing efficiency. For example, therobustness of the photolithographic process generally depends at leastin part on the lithographic system's ability to achieve focus when thetopography of the surface to be imaged deviates from an ideal. When thewarping or the degree of non-flatness of the substrate surface exceedsthe range of the depth of focus (DOF) of a system, a mask pattern imagedonto the photoresist layer on the substrate by the system will be out offocus in at least some regions on the substrate. This can result inflaws in the subsequent processing and lead to defective circuits ormicrostructures. One primary “flaw” of concern is achieving the desiredcritical dimension (CD) in terms of both size and shape of the feature.In short, excessive deviation of a substrate surface from the plane offocus of the photolithographic tools and processes represents a sourceof aberration from desired feature dimensions and resolution.

It is undesirable to use processes accompanied with unacceptable strainor warpage problems for other reasons as well. For example, theeffectiveness of photolithographic processes for semiconductor wafersdepends, often in part, on the alignment of a wafer under processing (orsurface and/or interior features thereof) with respect to a mask used inthe optical exposure of the photolithographic process. Misalignment of awafer under processing with respect to the mask is undesirable and canoccur when wafer strain is introduced in an uncontrolled manner. Whenmisalignment exceeds the tolerance range, a resultant circuit may berendered defective, thereby causing poor performance or even failure ofthe circuit. In short, uncontrolled stresses and strains accumulatedover a series of wafer layers may result in alignment problems thatresult in the formation of defective microelectronic components such astransistors for either negative-channel or positive-channelmetal-oxide-semiconductors (NMOS and PMOS).

Coherent and incoherent laser technologies may be used to carry outthermal processing semiconductor-based microelectronic devices such asprocessors, memories and other integrated circuits (ICs) that requirethermal processes. For example, the source/drain parts of transistorsmay be formed by exposing regions of a silicon wafer substrate toelectrostatically accelerated dopants containing boron, phosphorous orarsenic atoms. After implantation, the interstitial dopants areelectrically inactive and require activation. Activation may be achievedby heating the entirety or a portion of the substrate to a particularprocessing temperature for a period of time sufficient for the crystallattice to incorporate the impurity atoms into its structure. Typically,laser technologies are used to rapidly heat the wafer to temperaturesnear the semiconductor melting point to incorporate dopants atsubstitutional lattice sites, and the wafer is rapidly cooled to“freeze” the dopants in place.

A rapid thermal cycle is used to “activate” the dopant atoms in thejunction areas to avoid any appreciable change in the dopant atomdistribution. As a result, an ideal box-like activated dopant profile,as substantially defined by the implant process rather than by thesubsequent heating, is created. Exemplary terminology used to describelaser-based thermal processing techniques include laser thermalprocessing (LTP), laser thermal annealing (LTA), and laser spikeannealing (LSA). In some instances, these terms can be usedinterchangeably.

Laser processing techniques involving lasers and/or laser diodestypically involve forming a laser beam into a long, thin image, which inturn is quickly scanned across a surface to be heated, e.g., an uppersurface of a semiconductor wafer. For example, LTP may use a continuousor pulsed, high-power, CO₂ laser beam, which is coherent in nature. TheCO₂ laser beam is raster scanned over the wafer surface so all regionsof the surface are exposed to at least one pass of the heating beam.Similarly, a laser diode bar may be used to produce an incoherent beamfor scanning over the wafer surface.

In the time that it takes for the beam to pass over a particularlocation on the surface of the wafer, that location is raised to anannealing temperature. For example, raster scanning a 100-μm wide beamacross a wafer surface at a constant velocity of 100 mm/s may result ina 1-millisecond dwell time for the heating cycle. A typical maximumtemperature during this heating cycle might be about 1350° C. forsilicon wafers. Within the dwell time needed to bring the wafer surfaceup to the maximum temperature, a layer only about 100 to about 200micrometers below the surface region is heated. The bulk of themillimeter thick wafer serves to cool the surface almost as quickly asit was heated once the laser beam is past. Additional informationregarding laser-based processing apparatuses and methods can be found inU.S. Pat. No. 6,747,245 and U.S. Patent Application Publication Nos.2004/0188396, 2004/0173585, 2005/0067384, and 2005/0103998 each toTalwar et al.

Wafer warpage and strains are a well-known phenomenon in the art ofsemiconductor wafer processing. For example, implantation processes asdescribed above tend to create stresses in semiconductor wafers.Similarly, temperature gradients associated with wafer surface heatingalso tends to induce stress in wafers. As observed in U.S. Pat. No.6,865,308 to Conway et al., silicon wafers having layers deposited andannealed thereon at relatively high temperatures tend to become warped.In extreme cases, the wafer itself becomes so warped after a particularsubprocess that the wafer cannot be properly secured to stepper chucksfor subsequent subprocesses.

Laser-based semiconductor wafer processes, as discussed below, mayresult in undesirable strains and wafer warping. For example, laserspike annealing techniques has been extensively applied in currentsemiconductor industry for junction annealing to achieve excellentdevice performance. In the context of such applications, higherannealing temperatures are generally desirable because, as illustratedin FIG. 1, higher annealing temperatures tend to give rise to improveddevice performance. However, it has been observed that wafers processedusing scanned laser beams tend to become warped. In some instances, thewafer warpage generated during LSA process may exceed the tighttolerance required for IC manufacturing processes such as thoseinvolving photolithography. In particular, FIG. 2 shows that waferwarpage generally increases with higher LSA temperature.

Nevertheless, strain associated with semiconductor substrates such assilicon wafers does not necessarily poses a problem in all semiconductorprocessing contexts. For example, strain engineering has been widelyused recently to boost the transistor performance in silicon wafers. Inparticular, it has been observed that current flow may be improved byaligning strain with certain crystallographic and/or transistororientations.

Thus, there is a need to find solutions to mitigate wafer warpageproblems that may arise as a result of improved laser processingtechniques that involve increased processing temperatures. In addition,there are opportunities in the art to employ laser processing techniquesto produced improved microelectronic devices by providing a means toeffect wafer strain in a controlled manner.

SUMMARY OF THE INVENTION

In a first embodiment, the invention provides a system for processing asurface of a substrate. That system includes a radiation source, e.g., aCO₂ laser, a stage, a substrate-orienting means, and a controller. Theradiation source is adapted to emit a photonic beam suitable forprocessing the substrate surface. The stage is adapted to support andmove the substrate translationally relative to the beam. Thesubstrate-orienting means is effective for orienting the substraterotationally relative to the beam. The controller is operably coupled tothe radiation source, the stage, and/or the substrate orienting means isadapted to provide relative scanning motion between the stage and thebeam. As a result, the beam may be scanned translationally over thesubstrate surface along a first path at a first orientation anglefollowed by translational scanning over the substrate surface along asecond path at a second orientation angle. Typically, the beam isscanned translationally over substantially the entire substrate surfaceat first and second orientation angles.

Optionally, a relay may be provided to direct the beam toward thesubstrate surface at an incidence angle of at least 45° or substantiallyidentical to the Brewster's angle of the beam for the substrate surface.In some instances, the relay is adapted to form an elongate image on thesubstrate surface. Such an image may have a lengthwise axialdirectionality that traverses the relative translational scanning motionbetween the beam and the stage.

In some instances, the substrate-orienting means is adapted to alter thesubstrate from the first to the second orientation angle withoutremoving the substrate from the stage. In the alternative, the substratemay be removed from the stage to alter the substrate from the first tothe second orientation angle. In any case, the first and secondorientation angles may differ by about 90°.

In another embodiment, the invention provides a method for processing asurface of a substrate. The method involves generating a photonic beamsuitable for processing the substrate surface, scanning the beamtranslationally over the substrate surface along a first path at a firstorientation angle, and scanning the beam translationally over thesubstrate surface along a second path at a second orientation angle. Forsemiconductor wafer annealing applications, the photonic beam mayilluminate no more than 5% of the substrate surface at one time and iseffective to heat an illuminated portion of the substrate surface at arate of at least 1000° C. per second.

The substrate may be processed by scanning the beam translationally oversubstantially the entire substrate surface at the first and secondorientation angles. When the beam is scanned at substantially identicalrates for the first and second orientation angles, the processed surfacemay exhibit reduced surface warpage relative to a surface that isprocessed in its entirety at once and/or relative to a surface that isscanned at a single orientation angle.

Typically, the first and second paths, when viewed from the first andsecond orientation angles, respectively, are substantially identical toeach other. Thus, each of the first and second paths may coversubstantially the entire substrate surface. In the alternative, thefirst and second paths may be different. In some instances, one of thefirst and second paths covers substantially the entire substrate surfacewhile the other path covers only a selected portion of the substratesurface.

Each of the first and second paths may include a plurality of parallelsegments. The segments may be linear and/or curved and may be spaced ata predetermined distance from each other so the illuminated sectionsalong the parallel segments overlap. The predetermined distance isselected according to the intensity profile of the beam. The intensityprofile may have a peak intensity region and the predetermined distanceis selected so the peak intensity regions do not overlap.

In a further embodiment, the invention provides a method for processinga substrate to produce a desired surface contour. The substrate isproduced by a method that starts out with a substrate having a surfacehaving an initial surface contour profile. The method may involveproducing a photonic beam suitable for processing the substrate surfaceand scanning the beam translationally over the substrate surface along afirst path at a first orientation angle. As a result, the initialsurface contour is converted into an intermediate surface contour. Then,the beam is scanned translationally over the substrate surface along asecond path at a second orientation angle. The intermediate surfacecontour is then converted into the desired surface contour.

In yet another embodiment, the invention provides a method for reshapinga substrate having a surface with a contour unsuitable for subsequentprocessing. A photonic beam scans the beam translationally over thesubstrate surface along a selected path and a selected orientation angleto effect thermal processing. As a result, the surface is reshaped in amanner effective to convert the unsuitable surface contour into acontour suitable for subsequent processing.

In still another embodiment, a method is provided for improving theperformance of a microelectronic circuit on a surface of a semiconductorsubstrate. The method involves generating a photonic beam suitable forproducing a image having a shape and/or intensity profile suitable forthermally processing the substrate surface. The image is scannedtranslationally over the substrate surface at an orientation angleeffective to produce a surface strain in a manner that enhances carriermobility in the microelectronic circuit relative to carrier mobility ofthe circuit without the surface strain. The orientation angle may beselected to improve the performance of circuits that include PMOS and/orNMOS transistors.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graph that plots the percentage nMOSFET drive current gainrelative to a baseline over a range of annealing temperatures usinglaser scanning.

FIG. 2 is a graph that plots device wafer warpage over a range ofannealing temperatures using laser scanning, showing that warpageincreases with the annealing temperature.

FIG. 3 is a schematic side view of an exemplary laser thermal processinggeometry involving a substrate with an upper surface.

FIG. 4 is a plan view of a substrate surface and an exemplary image scanpath thereon having a plurality of linear segments.

FIG. 5 is a plan view of a substrate surface and an image scan pathhaving an arcuate segment.

FIG. 6 is a plan view of an exemplary scan path for a line image thattraverses over substantially an entire substrate surface, wherein thescan path includes a plurality of parallel arcuate scan path segmentscoupled to each other through transition segments that bring the lineimage off of and onto the substrate surface.

FIG. 7 is a close-up view of the scan path of FIG. 6, showing twotransition scan path segments connected to a turn-around scan pathsegment near the edge of the substrate.

FIG. 8 shows the typical “bowed” wafer topography after LSA processingusing a scan path similar to that shown in FIG. 4.

FIGS. 9A and 9B, collectively referred to as FIG. 9, depict scan pathsassociated with a two-step scanning process using two identical androtationally offset scan paths. FIG. 9A depicts the first scan path.FIG. 9B depicts the second scan path.

FIGS. 10A and 10B, collectively referred to as FIG. 10, depict scanpaths associated with a two-step scanning process using different scanpaths. FIG. 10A depicts the first scan path. FIG. 10B depicts the secondscan path.

FIGS. 11A and 11B, collectively referred to as FIG. 11, show the resultsof an experiment carried out to compare a two-step LSA process with asingle-step LSA process relative to substantially identicalboron-implanted silicon wafers. FIG. 11A shows asymmetric warpagebehavior typical of the single-step LSA process. FIG. 11B shows the moresymmetric warpage behavior typical of the two-step LSA process.

FIGS. 12A and 12B, collectively referred to as FIG. 12, show the resultsof an experiment carried out to compare a two-step LSA process with asingle-step LSA process relative to substantially identical SiGe. FIG.11A shows asymmetric warpage behavior typical of the single-step LSAprocess. FIG. 11B shows the more symmetric warpage behavior typical ofthe two-step LSA process.

FIG. 13 is a graph that plots measured surface curvature versus peaklaser annealing temperatures in lengthwise and widthwise beamdirections.

FIGS. 14A-14C, collectively referred to as FIG. 14, schematicallyillustrate various orientation relationships possible between the laserbeam image relative to transistor channel orientations. FIG. 14A shows abeam image having a lengthwise axis parallel to the longitudinaltransistor channel orientation. FIG. 14B shows a beam image having alengthwise axis perpendicular to the longitudinal transistor channelorientation. FIG. 14C shows a beam image having a lengthwise axis at aorientation angle θ of approximately 45° relative to the longitudinaltransistor channel orientation.

The drawings are intended to illustrate various aspects of theinvention, which can be understood and appropriately carried out bythose of ordinary skill in the art. The drawings may not be to scale ascertain features of the drawings may be exaggerated for emphasis and/orclarity of presentation.

DETAILED DESCRIPTION OF THE INVENTION Definitions and Overview

Before describing the present invention in detail, it is to beunderstood that this invention, unless otherwise noted, is not limitedto specific substrates, lasers, or materials, all of which may vary. Itis also to be understood that the terminology used herein is for thepurpose of describing particular embodiments only, and is not intendedto be limiting.

It must be noted that, as used in this specification and the appendedclaims, the singular forms “a”, “an” and “the” include both singular andplural referents unless the context clearly dictates otherwise. Thus,for example, reference to “a beam” includes a plurality of beams as wellas a single beam, reference to “a wavelength” includes a range orplurality of wavelengths as well as a single wavelength, and the like.

In describing and claiming the present invention, the followingterminology will be used in accordance with the following definitions.

The terms “Brewster's angle” or “Brewster angle” is used to refer to theangle of incidence between a radiation beam and a surface thatcorresponds to the minimum or near-minimum reflectivity of theP-polarized component of the beam. Films on the surface of an object,such as a silicon wafer, may prevent it from exhibiting zeroreflectivity at any angle. If, however, the films are dielectric innature, then there generally will be an angle of minimum reflectivityfor P-polarized radiation. Accordingly, the Brewster's angle as usedherein for a specular surface formed from a variety of different filmsstacked on a substrate can be thought of as having an effectiveBrewster's angle, or the angle at which the reflectivity of P-polarizedradiation is at a minimum. This angle of minimum reflectivity typicallycoincides with or is near the angle of the Brewster's angle for thesubstrate material.

The term “intensity profile” in reference to an image or a beam refersto the distribution of the integrated radiation intensity along one ormore dimensions. For example, an image may have a useful portion and anon-useful portion. The useful portion of an image typically has a“uniform” or constant integrated intensity profile over some portion ofits length. In other words, the intensity profile integrated in the scandirection throughout the useful portion of the image may besubstantially constant. Accordingly, any point on a substrate surfaceregion that is scanned by a useful portion of an image having a uniformintensity profile will be heated to the same temperature. However, theintensity or intensity profile of the non-useful portion may differ fromthat of the useful portion. Thus, the image as a whole may have anoverall “non-uniform” intensity profile even though a useful portion byitself may exhibit a uniform intensity profile.

As a related matter, the term “peak intensity region” of an image or abeam refers to the region along the beam length exhibiting the highestintegrated intensity across the beam width. Typically, the entirety ofthe useful portion of an image will exhibit an integrated intensity veryclose to the peak integrated intensity.

As another related matter, the term “energy utilization” as in the“energy utilization of an image” refers to the proportion of energyassociated with the portion of the image useful for producing a desiredeffect relative to the total beam energy in the image. For example, inan annealing application the “useful portion” of an image may be onlythat part of the beam that comes within about a percent or two of themaximum or peak beam intensity. In such a case, the “useful portion”exhibits a “substantially uniform” intensity. A small modification tothe image profile shape can produce a large change in the “energyutilization”.

The term “semiconductor” is used to refer to any of various solidsubstances having electrical conductivity greater than insulators yetless than good conductors, and that may be used as a base material forcomputer chips and other electronic devices. Semiconductors includeelements such as silicon and germanium and compounds such as siliconcarbide, aluminum phosphide, gallium arsenide, and indium antimonide.Unless otherwise noted, the term “semiconductor” includes any one or acombination of elemental and compound semiconductors, as well asstrained semiconductors, e.g., semiconductors under tension orcompression. Exemplary indirect bandgap semiconductors suitable for usewith the invention include Si, Ge, and SiC. Direct bandgapsemiconductors suitable for use with the invention include, for example,GaAs, GaN, and InP.

The terms “substantial” and “substantially” are used in their ordinarysense and refer to matters that are considerable in importance, value,degree, amount, extent or the like. For example, the phrase“substantially Gaussian in shape” refers to a shape that correspondspredominantly to the shape of a Gaussian probability distribution curve.However, a shape that is “substantially Gaussian” may exhibit somecharacteristics of a non-Gaussian curve as well, e.g., the curve mayalso include a non-Gaussian component.

Similarly, a “substantially uniform” intensity profile will contain arelatively flat portion where the intensity does not deviate more than afew percent from the profile's peak intensity. Preferably, the intensitydeviation is less than about 2%. Optimally, the intensity deviation isno more than about 1% or no more than about 0.8%. Other uses of the term“substantially” involve an analogous definition.

The term “substrate” as used herein refers to any material having asurface, which is intended for processing. The substrate may beconstructed in any of a number of forms, for example, a semiconductorwafer containing an array of chips, etc.

As alluded to above, the invention is generally directed to apparatusesand methods for thermally processing a substrate surface. A scannedphotonic beam is used to heat the surface rapidly to a high annealingtemperature to improve the performance of devices formed on thesubstrate surface. In particular, the invention takes advantage ofspecific laser orientation angles and scan paths to process the surfaceso as to effect rapid annealing thereof in a manner that does not resultin detrimental substrate warpage.

An Exemplary Laser Annealing System

To illustrate the novel and non-obvious aspects of the invention, FIG. 3schematically depicts a thermal processing apparatus 10 that may be usedto anneal and/or otherwise thermally process one or more selectedsurface regions of a substrate according to the present invention. LTPsystem 10 includes a movable substrate stage 20 having an upper surface22 that supports a semiconductor substrate 30 having an upper surface Pand a surface normal, N, thereto. Substrate stage 20 is operably coupledto controller 50. Substrate stage 20 is adapted to move in the X-Y planeunder the operation of controller 50 so the substrate can be scannedrelative to the image generated from radiation provided by radiationsource 110. The stage 20 may also controllably rotate substrate 30 aboutan axis Z which extends orthogonally relative to the X-Y plane. As aresult, the stage 20 may controllably fix or alter the orientation ofsubstrate 30 in the X-Y plane.

Optionally, the semiconductor substrate 30 may have a generally circularupper surface P and a surface normal N. Substrate 30 includes a sidewall 32 interfacing via substrate edge 33 to a narrow annular peripheralportion P_(p) of that circumscribes the central portion P_(c) of uppersurface P. Interface P_(i) defines the boundary between the centralportion P_(c) and the peripheral portion P_(p) of the upper surface P.In some instances, the central portion represents a region of thesubstrate where full yield is expected when producing semiconductordevices such as integrated circuits, and the peripheral portionrepresents an edge exclusion region, a portion of the substrate in whichyield is not expected and sometimes where no device or portion thereoflies. In such a case, the central portion may be considered to occupysubstantially the entire substrate surface.

The stage may include different components to carry out differentfunctions. For example, an alignment system may be provided to positionthe substrate on the stage at a variable orientation angle relative tothe surface normal. In such a case, the stage may independently controlthe substrate movement while the alignment system controls the substrateorientation.

The radiation source 110 is operably coupled to controller 50, and arelay 120 that serves to relay radiation generated by the radiationsource toward the substrate to form an image on its surface. In anexemplary embodiment, radiation source 110 is a CO₂ laser that emitsradiation at a wavelength λ_(H)˜10.6 μm (heating wavelength) in the formof beam 112. Alternatively, the radiation suitable for use with theinvention may include LED or laser diode radiation as well, e.g.,radiation having a wavelength of about 0.8 μm. Optionally, a pluralityof radiation sources may be employed. As shown, the laser 110 generatesan input beam 112 that is received by a relay 120 that is adapted toconvert the input beam to an output beam 140 that forms an image 150 onthe substrate.

Optionally, the intensity profile of the beam can be manipulated so aportion of the image intensity is rendered uniform about its peakintensity for even heating and high energy utilization. For example, therelay 120 may transform the input beam 112 into output beam 140. Therelay may be constructed in a manner to provide for desired coherentbeam shaping so the output beam exhibits a uniform intensity profileover a substantial portion thereof. In short, the relay 120 and theradiation source 110 in combination may stabilize, the directionality,intensity profile, and phase profile of the output beam to produce aconsistently reliable laser annealing system.

Beam 140 travels along optical axis A, which makes an angle θ with asubstrate surface normal N. Typically, it is not desirable to image alaser beam on a substrate at normal incidence, because any reflectedlight may cause instabilities when it returns to the laser cavity.Another reason for providing optical axis A at an incidence angle θother than at normal incidence, is that efficiently coupling of beam 140into the substrate 30 may best be accomplished by judicious choice ofincidence angle and polarization direction, e.g., making the incidenceangle equal to the Brewster's angle for the substrate and usingp-polarized radiation. In any case, the stage may be adapted to scan thesubstrate through the beam position while preserving or altering theincidence angle. Similarly, the stage may be adapted to control, fix orvary the orientation angle of the substrate relative to the beam.

Beam 140 forms image 150 at substrate surface P. In an exemplaryembodiment, image 150 is an elongate image, such as a line image, havingits lengthwise boundaries indicated at 152, and located within a planecontaining the incident beam axis and the surface normal (N). Lengthwiseboundaries for images having a substantially Guassian intensity profilemay represent the useful portion of the image for thermal processing.Accordingly, the incidence angle of the beam (θ) relative to thesubstrate surface may be measured in this plane. Surface incident angleθ may be, for example the (effective) Brewster angle for the substrate.

The controller may be programmed to provide relative movement betweenthe stage and the beam. Depending on the desired process parameters, thecontroller may provide different types of relative movement. As aresult, the image 150 may be scanned across different paths, e.g., asdiscussed in detail below, on the substrate surface to heat at least aportion of the substrate surface. Such scanning may be carried out in amanner effective to achieve a desired temperature within a predetermineddwell time, D, e.g., less than 1 millisecond. Scanning may typically beperformed in a direction that is orthogonal to the lengthwise axis ofthe image although this is not a firm requirement. Non-orthogonal andnon-parallel scanning may be carried out as well.

A means may also be included to provide feedback of the uniformity ofthe maximum temperature achieved. Various temperature measuring meansand methods may be used with the invention. For example, a detectorarray might be used to take a snap-shot of the emitted radiationdistribution over the surface or multiple snap-shots might be used toderive a map of the maximum temperature as a function of the positionacross the length of the beam image. Optionally, a means for measuringthe intensity profile of the beam on the substrate may be used as well.

Optimally, a real-time temperature measurement system may be employed.An exemplary temperature measurement system is described in U.S. PatentApplication Publication No. 2006/0255017, entitled “Methods andApparatus for Remote Temperature Measurement of a Specular Surface”published on Nov. 16, 2006. Such temperature measurement systems may beused to provide input to the controller so appropriate corrections canbe made possibly by adjusting the radiation source, the relay or thescanning velocity.

Scan Paths

As alluded to above, the system shown in FIG. 3 may be used to scan alaser image over a substrate surface in a number of different ways toaddress a number of processing issues. FIG. 4 depicts in plan view of anexemplary scan path 160 traveled by image 150 when irradiating substratesurface P when relative motion is provided between the beam segments. Asshown, the alternating back and forth or “X-Y” scan path includes aplurality of parallel linear scanning segments 162 along the Ydirection. The segments 162 are uniformly spaced with neighboringsegments spaced apart at a segment-to segment distance S. FIG. 4 alsoshows that path 160 allows image 150 to process substantially the entiresubstrate surface P.

Alternatively, as discussed in U.S. Pat. No. 7,238,915 to Grek et al.,scan paths having both linear and arcuate scan path segments may beemployed, e.g., to avoid edge damage. For example, FIG. 5 depicts inplan view substrate surface P being irradiated by radiation beam 140over a single scan path 160 traversed by line image 150. In FIG. 5, scanpath 160 starts off surface P at position 160A and along a linearsegment 162A past progressive positions 160B (located at substrate edge33), 160C and 160D. Line image 150 continues along scan path 160following an arcuate scan path segment 162B that is parallel withsubstrate edge 33. Segment 162B includes positions 160E and 160F. Atposition 160F, arcuate segment 162B connects to linear segment 162C.Thus, continuing along scan path 160, line image 150 traversesoff-surface position 160G.

FIG. 6 depicts in plan view an exemplary alternating back and forth scanpath that includes a plurality of parallel curved segments. As shown,scan path 160 includes an initial linear scan path segment 1621 thatbrings line image 150 initially into contact with substrate 30. Onceimage 150 falls completely on substrate surface P, the linear scan pathsegment 162I transitions to the first of a number of arcuate scan pathsegments 162C that follow the curvature of boundary P_(i). Adjacentarcuate scan path segments 162C have a similar shape that are laterallydisplaced by a predetermined distance. Typically the predetermineddistance is related to the length and intensity profile of line image150. In addition, arcuate segments 162C may each have a radius equal tothe substrate radius minus the width of the periphery region P_(p).

Arcuate scan path segments 162C are connected to transition scan pathsegments 162T where the image travels off of, and back onto, thesubstrate. Adjacent transition scan path segments 162T are connected viaturn-around segments 162R. FIG. 7 is a close-up view of a portion ofscan path 160 near the substrate edge 33 illustrating two transitionsegments connected by a turn-around segment 162R. Turn-around segments162R are located away from the substrate edge and off surface P so image150 does not fall on the substrate surface during the transition betweenadjacent scan segments when the scanning velocity changes substantially.The turn-around segments 162R have to be long enough so the stagevelocity can be reversed and brought up to the required speed before theline image again touches the substrate edge.

For any scan path, the controller 50 may be is programmed to move stage20 via control signals to cause substrate 30 to follow scan path 160. Asa result, substantially the entire substrate surface P is thermallyprocessed with radiation beam 20. This procedure requires, among otherthings, coordinated motion in the X and Y scanning axis of stage 20 toproduce an appropriate scan path.

Surface Warpage

As discussed above, higher annealing temperatures are generallydesirable because higher annealing temperatures tend to give rise toimproved device performance. However, it has been observed that wafersprocessed using scanned laser beams tend to become warped and thatwarpage generally increases with higher LSA temperature. It has now beendiscovered that warpage behavior may differ depending on scan path aswell as other parameters associated with thermal processing.

For example, it has been observed that LSA processes for wafers that usean alternating scan path similar to that depicted in FIG. 4 tend to bowwafers in the manner shown in FIG. 8. As shown, warpage in the Ydirection is much larger than that in the X direction, resulting in a“chip-like” profile. That is, FIG. 8 shows that wafers tend topreferentially bow in the lengthwise direction of the image scanned onthe wafer. As shown, warpage in the lengthwise direction may be greaterthan 5 times that in the widthwise direction.

Surface warpage is problematic because integrated circuit manufacturingprocesses typically require tight tolerance on wafer warpages forannealing processes. For silicon wafers of 300 mm diameter, thetolerance is typically on the order of 5 μm or less across its diameter.Thus, asymmetric warpage is particularly problematic because excessivewarpage in one direction may render a wafer unsuitable for subsequentprocessing, even if the wafer warpage in another direction conforms tothe process tolerances.

It has now been discovered that assymetric warpage may be reduced by amultiple-step process in which a beam is scanned translationally overthe substrate surface along a first path at a first orientation anglefollowed by translational beam scanning over the substrate surface alonga second path at a second orientation angle. For example, LSA systemsmay be adapted to carry out a two-step wafer annealing process at astepping size of full beam length. The process involves first scanning abeam translationally over a wafer surface along a first scan path. As aresult, the wafer surface may be asymmetrically warped. Then, the waferis rotated 90° before the beam is scanned again over the surface along asecond scan path. While the scan paths may be identical when viewed fromthe perspective of the beam, the scan paths, due to the wafer rotation,are rotationally offset from each other by 90°. As a result of thesecond scan, both the overall warpage of the surface as well as theasymmetry of the warpage may be reduced.

The scan paths of the above-described two-step wafer annealing processare depicted in FIG. 9. As shown in FIG. 9A, the first scan path 160Atraveled by image 150 includes a plurality of parallel linear scanningsegments 162 along the Y direction over the wafer. The segments 162 areuniformly spaced with neighboring segments spaced apart a segment-tosegment distance S which corresponds to the length of image 150 to allowthe image to process substantially the entire wafer surface. Then, asshown in FIG. 9B, the wafer is rotated 90° with segments 162 alignedalong the X direction. Again, the wafer is scanned by image 150. Thesecond scan path 160B is substantially identical to the first scan path160A before wafer rotation.

In some instances, multiple-step wafer annealing processes may employdifferent scanning paths. Different scanning paths may be advantageouslyused to increase the rate of processing throughput. As shown in FIG.10A, LSA systems may be adapted to carry out a two-step wafer annealingprocess, similar to that discussed above in the first scanning step,carried out with the beam scanned translationally over a wafer surfacealong a first scan path to allow the image to process substantially theentire wafer surface. However, after the wafer is rotated 90°, as shownin FIG. 10B, only an edge portion of the wafer is scanned to allow thesecond step to reduce the warpage resulting from the first step.

Experimental results show that laser induced wafer warpage may bereduced through the use of the invention. For example, an experiment wascarried out to compare a two-step LSA process with a single-step LSAprocess relative to substantially identical boron-implanted siliconwafers. Both processes involved using the same beam scanned at the samescan rate over the wafer surface. As a result, scanned regions for bothprocesses reached a substantially identical peak temperature of 1350° C.In addition, both processes used the same thermal budget. In the singlestep LSA process, the segment-to-segment distance corresponds to half ofthe image length. In contrast, the two-step LSA process involved twoscan paths rotationally offset from each other by 90° withsegment-to-segment distances that correspond to the image length.

Results of this experiment are shown in FIG. 11. FIG. 11A showsasymmetric warpage behavior typical of the single-step LSA process. FIG.11B shows the more symmetric warpage behavior typical of the two-stepLSA process. As the wafer warpage associated with the single-stepprocess and two-step processes were measured at 50.5 μm and 19.6 μm,respectively, it is apparent that the two-step process resulted in amore symmetric wafer surface and exhibited approximately a two-foldimprovement over the one-step process.

The experiment was repeated for SiGe wafers except at a lower peaktemperature of 1200° C. The results of the SiGe wafer experiments areshown in FIG. 12. As shown in FIG. 12A, the single-step processesyielded a warpage measurement of 450 μm whereas the two-step processes,shown in FIG. 12B, yielded a warpage measurement of 209 μm. Again, thetwo-step process resulted in a more symmetric wafer surface andexhibited approximately a two-fold improvement over the one-stepprocess.

While a number of factors may contribute to wafer warpage in the contextof laser annealing, experimental data tends to indicate that the shapeand intensity of the image formed on the substrate surface has a muchgreater effect on substrate strain than the directionality of the scanpath. Similarly, experimental results show that warpage can also bereduced by optimizing the laser beam orientation (long axis) withrespect to the crystallographic orientation of the substrate. Forexample, it is found that for a (100) silicon substrate with epitaxiallygrown Si_(x)Ge_(1-x) films, warpage will be smaller if annealed with alaser beam orientation parallel to <100> crystallographic directioncompared to <110> direction.

Thus, the invention provides, in another embodiment, a method forprocessing a surface of a substrate that involves generating a photonicbeam for processing the surface of a semiconductor substrate having apredetermined crystallographic orientation. The beam is directed to forman elongate image suitable for processing the surface. The image isscanned translationally over substantially the substrate surface in itsentirely at an orientation angle selected according to the predeterminedcrystallographic orientation. The predetermined crystallographicorientation may be selected to reduce wafer warpage.

Controlled Thermally Induced Strain

As alluded to above, laser beams, during an annealing processes, mayproduce localized stresses and strains that result in wafer warpage.Also as alluded to above, strain engineering has recently been used toboost transistor performance for microelectronic circuits onsemiconductor wafers. Thus, it should be evident that a laser beam'sshape, intensity, and/or orientation can be optimized with respect towafer crystal orientation and transistor layout so the induced straincan maximize the carrier mobility in the direction of carrier transportand hence improve the performance of transistors.

As an example, an elongate laser image having a length on the order ofmillimeters to centimeters and a width of approximately 100 micrometersmay be scanned on the surface of a silicon wafer to anneal the wafer.The peak surface temperature lies below the melting point of silicon andtypically within a range of about 1100° C. to about 1411° C. The time afixed point on the wafer is exposed to the laser image is on the orderof 0.1 to 3.0 milliseconds. The heat diffusion length in this time scaleis about 30 to about 200 micrometers which is much smaller than typicalwafer thickness of about 725 to about 775 micrometers. Hence only a thintop layer is effectively heated.

Models simulating a two-dimensional temperature distribution in asilicon wafer under a scanning laser show that both lateral and verticalheating are strongly localized. The steep thermal gradient causesnon-uniform thermal expansion. When heated, a surface will expand morethan the bulk silicon underneath it because of higher surfacetemperature. This leads to a compressive surface stress. After cooling,however, a residual tensile stress will develop if the distorted latticecan not fully recover to its room temperature equilibrium position. Dueto the large aspect ratio of a laser beam, the residual tensile stressis asymmetric in the short and long beam direction.

FIG. 13 shows measured curvature of a laser-annealed wafer as a functionof peak annealing temperature. The curvature is driven by the residualstress. Positive curvature indicates tensile stress. Stress in thelengthwise image direction is much larger than that in the widthwiseimage direction.

It should be noted that the performance of NMOS and PMOS devices may beoptimized in different ways due to the differences in piezo-resistancecoefficients for N-type and P-type silicon. The piezo-resistancecoefficient also depends on how electrical current flows with respect tocrystal orientation and uni-axial stress direction. For integratedcircuit applications, transistors are typically built on (100) siliconsubstrate with channel (current flow direction) parallel to <100> or<110> crystal orientation. Table I lists the percent of linear draincurrent enhancement per 100 MPa tensile stress for various combinationof channel orientations and stress directions. For <110> channel NMOS,tensile stress is desirable in both longitudinal and transversedirections, while for <110> channel PMOS, tensile stress is preferred inthe transverse direction while compressive stress is desired in thelongitudinal direction.

TABLE I Longitudinal Transverse Channel Device (Channel) (Width)Vertical Orientation Type Stress Stress Stress [110] NMOS 3.1 1.8 −5.3[110] PMOS −7.2 6.6 0.1 [100] NMOS 10.2 −5.3 −5.3 [100] PMOS −0.7 0.10.1

Thus, proper application of laser heating technology to induceasymmetrical tensile stress can be utilized to optimize the transistorperformance in view of silicon's anisotropic piezo-resistance property.For example, for an [100] channel NMOS on (100) Si substrate, thelengthwise beam direction, as shown in FIG. 14A should be parallel tothe channel layout during the scanning. This creates large longitudinaltensile stress that is beneficial yet only small transverse tensilestress that is undesirable to NMOS. The impact on PMOS is minimalbecause of much smaller piezo-resistance coefficients.

For an [110] channel layout on (100) substrate, the situation is morecomplicated. To maximize the NMOS performance, the lengthwise beamdirection should still be parallel to the NMOS channel orientation. Tomaximize the PMOS performance, however, the lengthwise beam directionshould be perpendicular to the PMOS channel orientation. Thus, one can,in principle, layout the NMOS channel orientation at 90° with respect toPMOS channel orientation to maximize the gain for both N & PMOS duringthe same laser scan. In any case, Table II summarizes the impact oflaser beam direction on transistor performance for (100) siliconsubstrate.

TABLE II Channel Impact Impact on Orientation Laser Beam Direction onNMOS PMOS [100] Parallel to channel orientation ++ 0 [100] Perpendicularto channel − 0 orientation [110] Parallel to channel orientation + −[110] Perpendicular to channel + + orientation

Nevertheless, the NMOS & PMOS channels are often positioned along thesame direction for better lithographic resolution. In this case,aligning lengthwise beam direction perpendicular to the channelorientation will maximize PMOS gain while also improve NMOS.Alternately, the beam can be directed at an angle with respect to thechannel orientation. By adjusting the angle, the tradeoff between NMOS &PMOS performance can be tuned. It is also possible to use multipleannealing scans with different orientation angles to achieve the desiredstress distribution. For example, one can align the lengthwise beamdirection parallel to the channel in a laser annealing scan andperpendicular to the channel in a subsequent laser-annealing scan. Thiscreates an accumulative residual tensile stress that is more symmetricin longitudinal and transverse channel directions. As a result, NMOSperformance is maximized with only small impact on PMOS.

VARIATIONS ON THE INVENTION

It will be apparent to those of ordinary skill in the art that theinvention may be embodied in various forms. For example, high-power CO₂lasers may be used to generate an image having a substantially Gaussianintensity profile, which, in turn, is scanned across a surface of asubstrate to effect rapid thermal processing, e.g., melt or non-meltprocessing, of the substrate surface. Such power levels may provideexposure energy doses of at least about 60 J/cm² over a 1 ms dwell time.Longer dwells require higher energies. The wavelength of the CO₂ laser,λ, is 10.6 μm in the infrared region, which is large relative to thetypical dimensions of wafer features, and may therefore be uniformlyabsorbed as the beam scans across a patterned silicon wafer with theresult that each point on the wafer is raised to very nearly the samemaximum temperature.

In addition, the stage may include different components to carry outdifferent functions. For example, an alignment system may be included toposition the substrate on the stage at a variable orientation anglerelative to the surface normal. In such a case, the substrate movementand alignment may be independently controlled.

Additional variations of the present invention will be apparent to thoseof ordinary skill in the art. Upon routine experimentation, thoseskilled in the art may find that the invention may be incorporated intoexisting equipment. Auxiliary subsystems known in the art may be used tostabilize the position and the width of the laser beam relative to therelay. Those of ordinary skill in the art will recognize that care mustbe taken to address certain operational issues relating to the practiceof the invention using powerful lasers to realize the full benefit ofthe invention.

It is to be understood that, while the invention has been described inconjunction with the preferred specific embodiments thereof, theforegoing description is intended to illustrate and not limit the scopeof the invention. Any aspects of the invention discussed herein may beincluded or excluded as appropriate. For example, beam combiningtechnologies and beam shaping technologies may be used by themselves orin combination. Other aspects, advantages, and modifications within thescope of the invention will be apparent to those skilled in the art towhich the invention pertains.

All patents and patent applications mentioned herein are herebyincorporated by reference in their entireties to an extent notinconsistent with the above disclosure.

1. A system for processing a surface of a substrate to produce a device,comprising: a radiation source adapted to emit a photonic beam suitablefor processing the substrate surface; a stage adapted to support andmove the substrate translationally relative to the beam; an alignmentsystem to position the substrate on the stage at a selected orientationangle relative to a surface normal of the stage; and a controlleroperably coupled to the radiation source, the stage, and the alignmentsystem, wherein the controller is adapted to provide a first relativescanning motion between the stage and the beam to allow the beam to scantranslationally over substantially the entire surface of the substratealong a first path at a first orientation angle followed by a secondrelative scanning motion between the stage and the beam to allow thebeam to scan translationally over at least a portion of the surface ofthe substrate along a second path at a second orientation angle withsaid first and second orientation angles each selected to optimizeperformance characteristics of said device.
 2. The system of claim 1,wherein the radiation source includes a CO₂ laser.
 3. The system ofclaim 2, wherein the radiation source includes a relay adapted to directthe beam toward the surface substrate at an incidence angle of at least45°.
 4. The system of claim 3, wherein the incidence angle issubstantially identical to the Brewster's angle of the beam for thesurface.
 5. The system of claim 3, wherein the relay is adapted to forman elongate image on the substrate surface.
 6. The system of claim 5,wherein the elongate image has a lengthwise axial directionality thattraverses the relative translational scanning motion between the beamand the stage.
 7. The system of claim 1, wherein the controller isadapted to allow the beam to scan translationally over substantially theentire substrate surface at said second orientation angle.
 8. The systemof claim 1, wherein the alignment system is adapted to alter thesubstrate from the first to the second orientation angle withoutremoving the substrate from the stage.
 9. The system of claim 1, whereinthe alignment system is adapted to remove the substrate from the stageto alter the position of the substrate from the first to the secondorientation angle.
 10. The system of claim 1, wherein the first andsecond orientation angles differ by about 90°.
 11. A method forprocessing a surface of a substrate, comprising: (a) generating aphotonic beam suitable for processing the substrate surface; (b)scanning the beam translationally over the substrate surface along afirst path at a first orientation angle; and (c) scanning the beamtranslationally over the substrate surface along a second path at asecond orientation angle.
 12. The method of claim 11, wherein thephotonic beam illuminates no more than 5% of the substrate surface atone time.
 13. The method of claim 11, wherein the photonic beam iseffective to heat an illuminated portion of the substrate surface at arate of at least 1000° C. per second.
 14. The method of claim 11,wherein steps (b) and (c) is carried out to allow the beam to scantranslationally over substantially the entire substrate surface at firstand second orientation angles.
 15. The method of claim 11, wherein thefirst and second paths, when viewed from the first and secondorientation angles, respectively, are substantially identical to eachother.
 16. The method of claim 15, wherein each of the first and secondpaths include a plurality of parallel segments.
 17. The method of claim16, wherein the parallel segments of each of the first and second pathsare linear.
 18. The method of claim 16, wherein the parallel segments ofeach of the first and second paths are curved.
 19. The method of claim16, wherein the parallel segments are spaced at a predetermined distancefrom each other such that the illuminated sections substrate along theparallel segments overlap.
 20. The method of claim 19, wherein the beamhas an intensity profile and predetermined distance is selectedaccording to the intensity profile.
 21. The method of claim 20, whereinthe intensity profile has a peak intensity region and the predetermineddistance is selected such that the peak intensity regions do notoverlap.
 22. The method of claim 11, wherein steps (b) and (c) areperformed at substantially identical scan rates.
 23. The method of claim11, wherein one of steps (b) and (c) is carried out to allow the beam toscan translationally over substantially the entire substrate surface andthe other of steps (b) and (c) is carried out to allow the beam to scanover only a selected portion of the substrate surface.
 24. A method forprocessing a substrate to produce a desired substrate surface contour,comprising: (a) providing a substrate having a surface having an initialsurface contour profile; (b) generating a photonic beam suitable forprocessing the substrate surface; (c) scanning the beam translationallyover the substrate surface along a first path at a first orientationangle, thereby converting the initial surface contour into intermediatesurface contour; and (d) scanning the beam translationally over thesubstrate surface along a second path at a second orientation angle,thereby converting the intermediate surface contour into the desiredsurface contour.
 25. A method for reshaping a substrate having a surfacewith a contour unsuitable for subsequent processing, comprising: (a)generating a photonic beam suitable for thermally processing thesubstrate surface; and (b) scanning the beam translationally over thesubstrate surface along a selected path and a selected orientation angleto reshape the surface in a manner effective to convert the unsuitablesurface contour into a contour suitable for subsequent processing.
 26. Amethod for thermally processing a semiconductor substrate having amicroelectronic circuit on a surface thereof, comprising: (a) generatinga photonic beam suitable for producing an elongate image suitable forthermally processing the substrate surface; and (b) scanning the imagetranslationally over the substrate surface at an orientation angleeffective to produce a surface strain in a manner the enhances carriermobility in the microelectronic circuit relative to carrier mobility ofthe circuit without the surface strain.
 27. The method of claim 26,wherein the microelectronic circuit comprises a PMOS transistor.
 28. Themethod of claim 26, wherein the microelectronic circuit comprises a NMOStransistor.
 29. The system of claim 1 wherein said stage is rotatableabout said surface normal to alter the position of the substrate fromthe first to the second orientation angle.
 30. The system of claim 1wherein said first and second orientation angles are selected so warpageof the substrate produced when the substrate surface is scanned at thefirst orientation angle is reduced by scanning of the substrate surfaceat the second orientation angle to optimize characteristics of saiddevice.
 31. The system of claim 1 wherein a shape and orientation of animage created on the surface of the substrate by the photonic beam isselected based on a crystallographic orientation of the substrate toreduce warpage of the substrate.
 32. The system of claim 31 wherein whensaid device being formed on said substrate is a transistor with aparticular channel orientation, an orientation angle of said image fromsaid photonic beam relative to the channel orientation is selectable tomaximize performance of said transistor when completed.